Prefabricated universal structural steel panel and panel system

ABSTRACT

The prefabricated universal structural steel panel and panel system includes a generally elongated rectangular panel having an opposed exterior and interior surfaces, an opposed first and second end portions, and an opposed first and second side edge portions. At least two stiffening ribs are integrally formed and embedded in the panel and extend longitudinally between first and second end portions. The first side edge portion is designed and configured with a beveled or tapered side edge portion, which has an elongated male connecting member integrally connected thereof and extending away from the interior surface. An elongated female connecting member is integrally connected to the second side edge portion and extends away from the interior surface. The elongated male connecting member of one panel cooperatively profile to mate with female connecting member of adjacent panel.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to prefabricated steel panel,and in particular to a prefabricated universal structural steel paneland panel system for constructing a building.

2. Description of the Related Art

The concept of prefabricated steel panels has a long history withnumerous areas of application, including the construction industry.Typically, prefabricated steel panels are employed for commercialapplication, such as prefabricated steel buildings. While someprefabricated steel panels are adaptable to be joined together to forman exterior wall panel, floor panel or roof panel, these panels arelimited to a fixed range of application. However, if a givenprefabricated steel panel is capable of performing a greater number offunctions it is potentially able to increase cost and labor savings. Inaddition, a prefabricated universal steel panel that is capable of arange of applications, such as internal walls, ceilings, exterior walls,floors, and roofs could lower the over cost of constructing thebuilding, such as a home, which potentially could be beneficial to thehome buyer. Furthermore, a prefabricated universal steel panel thatincorporates the structural components required to build a buildingstructural can reduce construction waste.

Accordingly, there is a need for a prefabricated universal structuralsteel panel, which is capable of application to virtually all aspects ofa given construction while retaining a suitable level of versatility forconstructing a variety of building components, such as interior andexterior walls, ceilings, floors, and roofs. Additionally, there is aneed for a prefabricated universal structural steel panel, which issuitable for domestic and commercial application and utilizes a minimalamount of material. Furthermore, there is a need for a steel panelsystem that connects the prefabricated steel panels in a manner, whichforms a structural component of the building. Thus, a universalstructural steel panel and panel system solving the aforementionedproblems is desired.

SUMMARY OF THE INVENTION

The prefabricated universal structural steel panel and steel panelsystem for constructing a building includes prefabricated universalstructural steel panel includes a generally elongated rectangular panelhaving an opposed exterior and interior surfaces, an opposed first andsecond end portions, and an opposed first and second side edge portions.The first side edge portion is designed and configured with a beveled ortapered side edge portion, which has an elongated male connecting memberintegrally connected thereof and extending away from the interiorsurface. An elongated female connecting member is integrally connectedto the second side edge portion and extends away from the interiorsurface. At least two stiffening ribs are integrally formed and embeddedin the panel and extend longitudinally between first and second endportions.

The elongated male and female connecting members are in substantiallycomplementary mating relationship with respect to each other, such thatwhen elongated male connecting member of one universal structural steelpanel is slidably interlocked with the elongated female connectingmember of an adjacent universal structural steel panel the two panelsare joined in a substantially continuous plane.

Advantageously, the prefabricated universal structural steel panelsystem provides an efficient method to erect the shell of residentialhouses or commercial buildings, including the walls, roof, ceiling, andsub-floor. Additionally, the prefabricated universal structural steelpanels have a generally uniform in configuration, which is adaptable fora variety of applications.

These and other advantages of the present invention will become readilyapparent upon further review of the following specification anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective view of a prefabricated universal structuralsteel panel according to the present invention.

FIG. 1B is a perspective view of a prefabricated universal structuralsteel panel according to the present invention.

FIG. 1C is a perspective view of a prefabricated universal structuralsteel panel according to the present invention.

FIG. 2 is an end view of a prefabricated universal structural steelpanel according to the present invention.

FIGS. 3A and 3 b is a top view of a prefabricated universal structuralsteel panel according to the present invention showing the panels beingassembled.

FIG. 4 is a partial exploded of a plurality of universal steel panelsbeing assembled to form a building structure, such as a wall structure,according to the present invention.

FIG. 5 is a partial top view of a wall structured formed from aplurality of universal steel panels with insulating material accordingto the present invention.

FIG. 6 is a detail view of FIG. 5, showing a corner wall connectionaccording to the present invention.

FIG. 7 is a detail view of FIG. 5, showing a perpendicular wallconnection according to the present invention.

FIG. 8 is a side elevational view of a building structure formed form aplurality of universal steel panels according to the present invention.

FIG. 9 is a front elevational view of a building structure formed form aplurality of universal steel panels according to the present invention.

FIG. 10 is a detail view of FIG. 8, showing a roof and wall connectionaccording to the present invention.

FIG. 11 is a detail view of FIG. 8, showing a roof and wall connectionaccording to the present invention.

FIG. 12 is a detail view of FIG. 9, showing a wall, floor, andfoundation connection according to the present invention.

FIGS. 13A and 13 b is a top view of a prefabricated universal structuralsteel panel according to the present invention showing a secondembodiment.

FIG. 14 is a schematic view of prefabricating a universal structuralsteel panel according to the present invention.

Similar reference characters denote corresponding features consistentlythroughout the attached drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Turning to the drawings, FIGS. 1A, 1B, 1C, and 2, show a preferredembodiment of a prefabricated universal structural steel panel 20, inaccordance with the present invention. Generally, the universalstructural steel panel 20 includes a generally elongated rectangularpanel having an opposed exterior and interior surfaces 22, 24, anopposed first and second end portions 26, 28, and an opposed first andsecond side edge portions 30, 32. The first side edge portion 30 isdesigned and configured with a beveled or tapered side edge portion 34.In addition, the panel 20 includes stiffening ribs 34 and 36, which areintegrally formed and embedded to the panel 20 and extend longitudinallyfrom first and second end portions 26, 28. Although the preferredembodiment of the panel 20 is substantially rectangular shape, the panel20 can be fabricated in a variety of different shapes. For example, thepanel 20 can be a substantially square, oblong or trapezoidal shape.

An elongated male connecting member 40 is integrally connected to thefirst side edge portion 30 and extends away from the interior surface24. The elongated male connecting member 40 defines a support member,such as a beam, having a generally U-shape or C-shape configuration. Theelongated male connecting member 40 includes a web 42 and a first andsecond legs 44, 46 extending from opposite sides thereof. The first andsecond legs 44, 46 are in a generally parallel orientation with eachother and have substantially similar length and width. The end portionof the first leg 44 is integrally connected to the beveled or taperedside edge portion 34 of the first side edge portion 30.

An elongated female connecting member 50 is integrally connected to thesecond side edge portion 32 and extends away from the interior surface24. The elongated female connecting member 50 defines a support member,such as a beam, having a generally U-shape or C-shape configuration. Theelongated female connecting member 50 includes a web 52 and a first andsecond legs 54, 56 extending from opposite sides thereof. The first andsecond legs 54, 56 are in a generally parallel orientation with eachother and have substantially similar length and width. The end portionof the first leg 54 is integrally connected to second side edge portion32 and extends adjacent to the interior surface 24 to define a fold 60thereof. The fold 60 has a width and length that is generally similar tothe width and length of the first leg 54.

The webs 42 and 52 have an outer face 42 a, 52 a and an inner face 42 b,52 b, respectively, and a plurality of apertures 48, 58 extendingthrough the outer and inner faces 42 a, 52 a, and 42 b, 52 b. When theelongated male connecting member 40 of one panel 20 is slidablyinterlock with the elongated female connecting member 50 of adjacentpanel 20, the apertures 48 and 58 are in alignment with respect to eachother to define utility passageways for utility services, such aselectrical wiring, heating and ventilation pipes/conduits, and plumbing,to pass through the adjoined panels 20.

Preferably, the elongated male and female connecting members 40, 50 areformed from rolling the elongated rectangular panel 20 through rollers.More preferably, the panel 20 is prefabricated from a sheet of steel 222by a roll form machine 216, which has rollers 224 designed andconfigured to form the elongated male and female connecting members 40and 50, respectively, as describe further below. The steel used tofabricate the panel 20 can be of any type of steel. Preferably, theprefabricate universal structural steel panel 20 is galvanized steel.

Referring to FIGS. 3A and 3B, the elongated male connecting member 40 ofpanel 20 is cooperatively profile to mate with the elongated femaleconnecting member 50 of adjacent panel 20. The elongated male connectingmember 40 is slidably interlocked into the elongate female connectingmember 50 so that the outer face portion 42 a of web 42 is in abuttingrelationship with inner face portion 52 b of web 52 and the outer faceportions 44 a, 46 a of legs 44, 46 are in abutting relationship with theinner face portions 54 b, 56 b of legs 54, 56, respectively. Theadjoined elongated male and female connecting members 40 and 50 furtherdefine a support member, such as, for example, a load-bearing beam.

The outer face portion 44 a of the first leg 44 is offset relative tothe exterior surface 22 so that when the end portion of the first femaleleg 54 is adjacent to the bevel or taper 34 side edge portion, theexterior surfaces 22 of the adjoined panels 20 are relatively flush withrespect to each other in a substantially continuous plane.

FIG. 4 shows the universal structural steel panels 20 being assembled toform a building shell 90, in accordance with the present invention. Asillustrated, a plurality of panels 20 are slidably interlocked andjoined with each other to construct a building component 92. Thebuilding component 92 can be the walls, floor, ceiling, and roof of thebuilding shell 90, as described below.

The building component 92 is constructed in the following manner. Theelongated male connecting member 40 of panel 20 is in complementarymating relationship with elongated female connecting member 50 of theadjacent panel 20. The elongated male and female connecting members 40,50 are positioned in substantially parallel relationship with eachother, so that when elongated male connecting member 40 slidablyinterlocks to the elongated female connecting member 50 of the adjacentpanel 20, the panels 20 are joined in a substantially side edge-to-sideedge and co-planer orientation.

A first connecting member 70 and second connecting member 80 arepositioned in substantially parallel relationship with respect to eachother and are joined to the first and second end portions 26, 28,respectively, by a plurality of fasteners 66. Thereafter, the adjacentpanel 20 is positioned in mating relationship relative to the new panel20, which is being installed. The foregoing procedure is followed untila desired length and width of the wall, roof, ceiling and/or floor isconstructed. For example, if an 8-foot long wall is desired, then sixpanels 20 can be joined and interlocked together to form the 8-foot longwall section.

After the panels 20 have been assembled an optional step is to insulatethe wall, floor, ceiling, or roof section with an injection ofinsulation material, such as a high density Class 1 isofoampolyisocyanate, also known as polyurethane insulation material. Theinsulation is injected into the panels 20 and adheres to all interiorsurfaces therein. Advantageously, the injection of the insulationmaterial into the panels 20 increases the rigidity of the buildingcomponent 92.

Additionally, once the universal structural steel panels 20 are joinedtogether, a plurality of fasteners 66 can be used to further secure thepanels 20 to each other. The fasteners 66 can be screws, threadedfasteners with nuts attached thereon, or rivets or, alternatively, thepanels can be spot welded or bonded together by an adhesive.Furthermore, when fasteners 66 are used to secure the elongated maleconnecting member 40 to the elongated female connecting member 50, thefasteners 66 are attached at the center portion of the webs 42 and 52.

For example, the fasteners 66 could be generally spaced apart at anequal distance from each other along the longitudinal centerline of theinterlocked panels 20. Alternatively, the prefabricated universalstructural steel panels 20 can be permanently attached thereto bygenerally spaced spot-welds or any other suitable connecting method,which is in compliance with the Uniform Building Code of the area wherethe building is being constructed.

As illustrated further in FIG. 4, the first and second connectingmembers 70, 80 are generally oriented in a parallel configuration withrespect to each and with longitudinal lengths similar to the length ofthe assembled panels 20, so that the opposing end portions of the firstand second connecting members 70, 80 are relatively flush with the endsections of the assembled panels 20. Fasteners 66 are used to join hefirst and second connecting members 70, 80 to the first and second endportions 26, 28, respectively, to form a generally rectangular buildingcomponent 92.

The first and second connecting members 70, 80 are generally U-shapemembers having a web portions and first and second legs, which havesubstantially similar widths and lengths. Preferably, the first andsecond connecting members 70, 80 are U-shaped steel members. When thefirst and second connecting members 70, 80 are employed as part of awall component, the first and second connecting members 70, 80 definehat channels. Alternatively, the first and second connecting members 70,80 can be a generally C-shape metal member.

The first and second connecting members 70, 80 each include a web 72, 82and first and second legs 76, 86 and 74, 84, respectively, extendingoutwardly from opposite sides of the web 72 and 82. The first and secondlegs 76, 86 and 74, 84, are oriented in a generally parallelconfiguration with respect to each other and are substantially equal inlength and width, such that the first and second legs 76, 86 and 74, 84,are generally the same dimension. The first and second connectingmembers 70 and 80 are configured so that the webs 72 and 82 abut thefirst and second end portions 26, 28 of the panels 20. The first andsecond end portions 26, 28 are received between the legs 74, 76 of thefirst connecting member 70 and the legs 84, 86 of the second connectingmember 80.

With the universal prefabricated structural steel panels 20 and thefirst and second connecting members 70, 80 in place as described, thefirst and second legs 44, 54 and 46, 56 of the elongated male and femaleconnecting members 40, 50 are joined to the respective first and secondlegs 76, 86 and 74, 84 of the first and second connecting members 70,80. With this, the building component 92 is rigidly formed.

The joining method used to join the panels 20 and the first and secondconnecting members 70, 80 certainly could be accomplished in a number ofways that would occur to one skilled in the art. For example, the panels20 and the first and second connecting members 70, 80 could be joined byspot welding, by fasteners, such as metal screws, bolts and nuts,rivets, by clinching methods, or by adhesive.

FIG. 5 illustrates a stage of construction where the panels 20 are beingassembled to form a wall component 94 according to the panel system ofthe present invention. The wall component 94 is constructed from theuniversal structural panels 20, as described above. In this arrangement,the universal structural steel panels 20 define wall panels 20.

The first connecting member 70 is not shown in order to provide a viewof the various panel connections within the walls 96, 98. The walls 96,98 are constructed by interlocking the panels 20, as described above.Two typical wall configurations are depicted. The first configuration isa typical perpendicular wall connection where first wall 96 is joined tosecond wall 98 to form a typical exterior wall to interior wallcomponent of a building. However, a typical interior wall to interiorwall component can be formed by this arrangement. The secondconfiguration is a typical corner wall connection where first wall 96 isjoined to second wall 98 to form an exterior wall component. However, aninterior wall component can be formed by this arrangement.

FIG. 6 shows further detail of a typical corner wall connection. At thiscorner connection, two conventional panels 20, as described above, areused. The two panels 20 are positioned adjacent to each other so that anend portion of first leg 54 of the elongated female connecting memberabuts the outer face 46 a of second leg 46 of the elongated maleconnecting member. The web 50 of elongated female connecting member isjoined to the second leg 46 of elongated male connecting member byfastener 68, which can be a plurality of fasteners.

A corner member 100 is positioned adjacent to the exterior surfaces 22of the two panels 20 to form the corner wall component. The cornermember 100 has a first leg 102 and second leg 104 that are integrallyconnected together and extend at approximately a 90 degree angle thereofto define a generally L-shape corner member 100. The L-shape cornermember 100 is joined to exterior surfaces 22 of panel 20 of the firstwall 96 and panel 20 of second wall 98 by fasteners 66, which can be aplurality of fasteners 66. The L-shape corner member 100 is preferablysteel. More preferably, the L-shape corner member 100 is galvanizedsteel.

A reinforcing support member 106 is disposed adjacent to the panels 20for providing support to walls 96, 98 and for mounting gypsum board 114or other suitable materials thereon. The reinforcing support member 106has a web 108 and a first and second legs 110, 112 extending fromopposite sides thereof. The first and second legs 110, 112 are in agenerally parallel configuration with respect to each other. When thereinforcing support member 106 is employed as part of the wall component94, the reinforcing support member 106 defines a stud having a generallyU-shape configuration. Alternatively, the reinforcing support member 106could define a stud having a generally C-shape configuration with afirst and second flanges integrally connected to the end portions offirst and second legs 110, 112, respectively, and extending inwardlythereof.

The reinforcing support member 106 is positioned inside wall 96 with thefirst leg 110 adjacent to the interior surface 24 of panel 20. Thesecond leg 112 of reinforcing support member 106 is adjacent to thesecond leg 56 of elongated female connecting member 50. The second legs56, 108 are arranged in orientation with respect to each other in arelatively 90 degree angle, such that second legs 56, 108 define aninterior corner wall surface for mounting gypsum board 114 thereon.Insulation 64 is disposed inside wall 96, 98 between the gypsum board114 and interior surface 24 of the panels 20. The reinforcing supportmember 106 is preferably a steel stud, which is welded or fastened tothe panels 20. More preferably, the reinforcing support member 106 isgalvanized steel.

FIG. 7 shows further detail of a typical perpendicular wall connection.At this perpendicular connection, three conventional panels 20, asdescribed above, are used. The two panels 20 form part of first wall 96and are interlocked with each other, as described above. A firstreinforcing structural member 106 is positioned adjacent to elongatedfemale-connecting member 50, so that web 52 abuts web 108. A fastener ora plurality of fasteners 66 are used to join the reinforcing supportmember 106 to load-bearing support member 62, which is formed by theelongated male connecting member 40 being adjoined to the elongatedfemale connecting member 50.

A second reinforcing support member 106 is positioned inside wall 96with the first leg 110 adjacent to the interior surface 24 of panel 20.The second leg 112 of reinforcing support member 106 is adjacent to thesecond leg 56 of elongated female connecting member 50, which forms partof second wall 98. The second legs 56, 108 are orientated in arelatively 90-degree angle with respect to each other, so that secondlegs 56, 108 define an interior corner wall surface for mounting gypsumboard 114 thereon. Insulation 64 is disposed inside walls 96, 98 betweenthe gypsum board 114 and interior surface 24 of the panels 20.

One knowledgeable in the art will be aware that a plurality of fasteners66 and 68 can be used to secure the panels 20 and connecting wallcomponents together, as illustrated in FIGS. 6 and 7. Additionally, thefasteners 66 and 68 used to secure the first wall 96 to the second wall98 can be screws, bolts and nuts, or rivets. Alternatively, the panels20 and connecting wall components can be secured by any conventionalmethod, such as, spot welding or an adhesive.

Referring to FIGS. 8 and 9, the universal structural steel panels 20 areassembled to construct a building 90 pursuant to the panel system of thepresent invention. The building 90 can be residential or commercial andcan be single story or multilevel.

As can be appreciated by one skill in the art, the universal structuralsteel panels 20 can be adapted to carry different structural loadrequirements of the building 90. Accordingly, the thickness of the sheetof steel used to fabricate the panels 20 can be increased or decreasedto satisfy the various load requirements of the wall component 94, roofcomponent 150, and floor component 130, which are joined together toform the building 90.

Additionally, the panels 20 can be constructed and arranged to fitwithin each other to increase the overall thickness of the universalstructural steel panel. For example, a second panel 20 can be insertedinside a first panel 20 to double the thickness of the first panel 20.Similarly, a second and third panel 20 can be inserted inside a firstpanel 20 to treble the thickness of the first panel 20.

As described above, the universal structural steel panels are joinedtogether to construct the building component 92, which are the floor130, the wall 94, and the roof and ceiling 150 of a building shell 90.Accordingly, the floor 130, the wall 94, and the roof and ceiling 150include a plurality of panels 20 joined to each other by interlockingthe elongated male connecting member 40 of one panel 20 with theelongated female connecting member 50 of adjacent panel 20. The firstand second connecting members 70, 80 are connected to the first andsecond end portions 26, 28, respectively, of the interlocked panels 20to construct the building component 94 (as illustrated in FIG. 4), whichforms a generally rectangular building component. The buildingcomponents 94 define the floor 130, roof and ceiling 150, and wall 94components.

The floor components 130 are connected to each other side-by-side andend-to-end to construct the floor 130. In this configuration, theuniversal structural steel panels 20 define floor panels 20. The floorpanels 20 are positioned on the foundation so that the exterior surfaces22 face in an upwardly direction to receive a sub-floor sheathing. Thesub-floor sheathing is connected to the exterior surfaces 22 byconventional construction methods.

As described above, the load-bearing support member 62 is defined by theelongated male connecting member 40 being interlock to the elongatedfemale connecting member 50. When the panels are joined together in anarrangement to form the floor 130, the load-bearing support members 62define floor trusses. The legs 46 and 54 of elongated male and femaleconnecting members 40 and 50 are positioned adjacent to the foundation132 and the I-Beam 134.

The load-bearing support members 62 and legs 46 and 54 of elongated maleand female connecting members 40 and 50, respectively, are attached tothe foundation 132 and I-beams 134 by conventional construction methods,such as anchor bolts 144. Preferably, ½-inch diameter anchor bolts 144are used to secure the floor 130 to the foundation 132. Although afoundation wall is illustrated in FIGS. 8 and 9, the panels 20 can beattached to any type of foundation, such as a concrete slab, basementwall, columns, I-beams, or any other foundation used to support thebuilding 90.

The wall components 94 are constructed as described above. The wallcomponents 94 are assembled with a predetermined number of openings 120for the placement of fixtures, such as doors and windows. The window anddoor openings 120 include headers 122, jambs 126, and sills 124, whichform the door and window frames. The wall components 94 are connected toeach other side-by-side with second connecting member connected to floor130 and first connecting member 70 connected to the roof 150.Alternatively, first connecting member 70 can be connected to a ceiling,which is defined by a second floor 130 of a multi-story or multi-levelbuilding 90. When the building 90 includes multiple stories/levels, wall94 of a second story is stacked on top of wall 94 of the first levelwith a second floor 130 disposed between the first story wall and thesecond story wall.

Similar to the floor 130, when the panels 20 are joined to form the roof150, the load-bearing support members 62 define roof trusses. The roofcomponents 150 are connected to each other side-by-side and end-to-endto construct the roof 150. In this configuration, the universalstructural steel panels 20 define roof panels 20. The roof panels 20 areconnected to the wall components 94 to form the building 90. A facia cap154 extends around the exterior perimeter of the roof 150.

FIG. 10 shows the roof 150 joined to the wall 94 by a ridge beam 152.The ridge beam 152 is formed from two substantially similar pieces,which are fastened together by fasteners 158. The fasteners 158 can bescrews, bolts and nuts, or rivets. Alternatively, the two pieces of theridge beam 152 could be welded together. The ridge beam 152 is fastenedto the first connecting member 70, which defines the top hat channel ofthe wall 94, by fasteners 158.

A first roof panel 20 is positioned on top of the first piece of theridge beam 152 and a second roof panel 20 is positioned on second pieceof the ridge beam 152 so that first and second connecting members 70, 80are adjacent to each other. The first and second connecting members 70,80 define roof tracks 156. A ridge cap 160 is connected to the exteriorsurfaces 22 of the adjacent roof panels 20 by fasteners 158. Insulation64 is disposed inside the roof 150 and the wall 94.

FIG. 11 shows the roof 150 joined to the wall 94 by two connectingbrackets 160, 162. Bracket 162 is substantially V-shaped and bracket 160is substantially L-shaped with one leg portion extending at an anglerelative to the other leg portion. The brackets 160, 162 are positionedon opposite sides of wall 94. Brackets 160 and 162 are connected to theroof panel 20 and to wall 64 by fasteners 158, such as screws, bolts andnuts, rivets or, alternatively, by spot welding or an adhesive.

FIG. 12 shows further detail of the connection between the wall 94, thefloor 130 and the foundation 132. The wall panel 20 is connected to thesub-floor sheathing 142 by conventional construction joining methods,such as anchor bolts, nails, adhesives, glue, or screws. Similarly, thefloor panels are joined to the sub-floor sheathing 142 and to the woodsill 140 by conventional construction joining methods, such as anchorbolts, glue, adhesives, nails, or screws. The wood sill 140 is anchoredto the foundation 132.

In more detail, the second connecting member 80 defines a hat channel,which is anchored to the sub-floor sheathing 142. The corner member 100is connected to the exterior surface of the panel 20 and the secondconnecting member 80 by fasteners 66. A floor paneling cap 138, which isdefined by first or second connecting members 70, 80 is cooperativelyprofiled to mate with elongated female connecting member 50. Fasteners66 secure the floor-paneling cap 138 to the panels 20.

FIGS. 13A and 13 b depict an alternative embodiment of the inventionthat is substantially identical to the above-described embodiment of theuniversal structural steel panel 20 except that elongated male andfemale connecting members 40, 50 have a different configuration. Asdescribed above, elongated male and female connecting members 40, 50 arecooperatively profiled to mate with each other so that the universalstructural steel panels 20 are joined together in a substantiallycontinuous plane with the exterior surfaces 22 being generally flushwith each other. Elongated male connecting member 40 includes a web 42having a generally V-shape configuration. First and second legs 44, 46are integrally connected to opposite end portions of the V-shaped web 42and extend outwardly thereof in a substantially parallel relationship toeach other.

Similarly, elongated female connecting member 50 includes a web 52having a generally V-shape configuration with first and second legs 54,56 integrally connected to opposite end portions and extending outwardlythereof in a substantially parallel relationship to each other. Legs 54and 44 are integrally connected to first and second side edge portions30 and 32, respectively. When elongated male connecting member 40 ofpanel 20 is slidably received into elongated female connecting 50 ofadjacent panel 20, the panels 20 interlock with each other to form aportion of the building 90, such as the wall, roof, or floor component.

FIG. 14 shows the method of making the universal structural steel panels20 according to the present invention. The panel fabricating system 200for fabricating the universal structural steel panels 20 includes anuncoiler 210, a flattener and slitter 212, a pre-punch/press die 214, aroll former machine 216, a cut-off machine 218, and a run-out anddischarge conveyor systems 220. The panel fabricating system 200 isautomated and the plurality of rollers 224 are designed and configuredto form the panel 20, as described above, from a substantiallycontinuous sheet of steel.

In operation, steel 222 is uncoiled from a roll of steel by the uncoiler210 and feed into the flattener and slitter apparatus 212 where theunrolled sheet of steel 222 is formed as a relatively flat sheet ofsteel and slotted at predetermined locations for punching holes. Thesheet of steel is feed into the pre-punch/press die machine where thesteel is punched to form holes/apertures 48, 58 and then stiffening ribsare pressed into the relatively flat sheet of steel for feeding into aroll former machine 216. The holes/apertures 48, 58 are generally ovalshaped with a diameter of approximately 1 to 3 inches and a length ofapproximately 1 to 6 inches.

Next, the sheet of steel 222 is feed into the roll former machine 216where a plurality of rollers 224 form and shape the panel 20 into itspreferred embodiment, as described above. The panel 20 is then feedthrough the cut-off machine, where the panel 20 is cut at apredetermined length. The length of the panel 20 will vary depending onwhether the panel is being fabricated for a wall 94, roof 150, or floor130 component of the building. Accordingly, the panels 20 will have ageneral length of approximately 8 to 20 feet. For example, a typicalwall length in the construction industry is 8 feet. Accordingly, thewall panel 20 will have a general length of 8 feet. The panel 20 isdischarged from the panel fabricating system 200 by a run-out anddischarge conveyor systems 220. The foregoing procedure is followeduntil a desired number of panels 20 are fabricated.

The steel used for making the panels 20 is preferably galvanized steel.More preferably, G-60 galvanized steel. The thickness of the sheet ofsteel 222 can vary depending on the load requirements of the buildingand the application of the panel 20. Generally, the steel 222 beingrolled through the rollers 224 will have a thickness range from 12 to 30gauges. The thickness of the panels 20 will depend on their application.For example, the panel 20 will have range in thickness from 26-gaugesteel to 12-gauge steel depending on whether the panel 20 is used toconstruct the wall, floor, ceiling, or roof components of the building.

Although the invention has been described in language specific tostructural features and/or methodological steps, it is to be understoodthat the invention defined in the appended claims is not necessarilylimited to the specific features of steps described. Rather, thespecific features and steps are disclosed as preferred forms ofimplementing the claimed invention.

1. A universal structural steel panel system, comprising: at least oneelongated panel having opposing exterior and interior surface, opposingfirst and second end portion, and opposing first and second side edgeportion; an elongated male connecting member integrally connected to thefirst side edge portion and extending away from the interior surface ofsaid at least one elongated panel; an elongated female connecting memberintegrally connected to the second side edge portion and extending awayfrom the interior surface of said at least one elongated panel; saidelongated male connecting member of said at least one elongated panelcooperatively profiled to slidably interlock with said elongated femaleconnecting member of an adjacent at least one elongated panel; andwherein said elongated male connecting member and said elongated femaleconnecting member of said at least one elongated panel are formed byrolling said at least one elongated panel.
 2. The universal structuralsteel panel system according to claim 1, wherein said at least oneelongated panel is of a substantially rectangular shape.
 3. Theuniversal structural steel panel system according to claim 1, whereinsaid at least one elongated panel is constructed of galvanized steel. 4.The universal structural steel panel system according to claim 1,wherein said at least one elongated panel includes at least twostiffening ribs integrally embedded to said at least one elongatedpanel, said at least two stiffening ribs extending longitudinally fromthe first end portion to the second end portion.
 5. The universalstructural steel panel system according to claim 1, wherein the firstside edge portion is tapered.
 6. The universal structural steel panelsystem according to claim 5, wherein the tapered first side edge portionis integrally connected to said elongated male connecting member.
 7. Theuniversal structural steel panel system according to claim 1, whereinsaid first elongated male connecting member of said at least oneelongated panel and said second elongated female connecting member ofsaid adjacent elongated panel are positioned in a substantially parallelmating relationship with respect to each other for orienting said atleast one panel relative to said adjacent elongated panel in asubstantially side edge-to-side edge and co-planer relation.
 8. Theuniversal structural steel panel system according to claim 1, whereinsaid at least one elongate panel comprises a plurality of elongatedpanels joined together, said joined plurality of elongated panelsfurther comprising a first connecting member having a web portion andfirst and second legs and a second connecting member having a webportion and first and second legs, said first connecting member beingconnected to first end portions of said joined plurality of elongatedpanels, said second connecting member being connected to second endportions of said joined plurality of elongated panels, wherein saidjoined plurality of elongated panels define a building component forconstructing a building.
 9. The universal structural steel panel systemaccording to claim 8, wherein the building component is a plurality ofbuilding components comprising of walls, roof, ceilings, and floor, saidplurality of building components are joined together to define abuilding shell.
 10. A universal structural steel panel system,comprising: a plurality of elongated rectangular steel panels havingopposing exterior and interior surfaces, opposing first and second endportions and opposing first and second side edge portions; an elongatedmale connecting member having a web and first and second legs extendingsubstantially parallel to each other from opposing sides thereof, saidelongated male connecting member integrally connected to the first sideedge portions of said plurality of rectangular steel panels; anelongated female connecting member having a web and first and secondlegs extending substantially parallel to each other from opposing sidesthereof, said elongated female connecting member integrally connected tothe second side edge portions of said plurality of rectangular steelpanels; said elongated male connecting member cooperatively profiled toslidably interlock with opposing said elongated female connecting memberon adjacent said plurality of elongated rectangular steel panels,wherein said plurality of rectangular steel panels are joined togetherby interlocking said elongated male connecting member to said elongatedfemale connecting member; a first connecting member having a web portionand first and second legs, said first connecting member being connectedto first end portions of said plurality of elongated rectangular steelpanels; a second connecting member having a web portion and first andsecond legs, said second connecting member being connected to second endportions of said joined plurality of elongated rectangular steel panels;and wherein said plurality of elongated panels define a buildingcomponent for constructing a building.
 11. The universal structuralsteel panel system according to claim 10, wherein said elongated maleand female connecting members define a plurality of apertures, saidplurality of apertures configured and arranged in alignment with respectto each other when said elongated male connecting member interlocks tosaid female connecting members.
 12. The universal structural steel panelsystem according to claim 10, wherein said elongated rectangular steelpanels includes an insulation material disposed on interior surface saidplurality of elongated rectangular steel panels.
 13. The universalstructural steel panel system according to claim 10, wherein theconnection between said elongated female connecting member and thesecond side edge portion of said plurality of rectangular steel panelsdefines a fold.
 14. The universal structural steel panel systemaccording to claim 10, wherein the connection between said elongatedmale connecting member and the first side edge portion of said pluralityof rectangular steel panels defines a bevel.
 15. The universalstructural steel panel system according to claim 10, wherein saidplurality of elongated rectangular steel panels includes at least onestiffening rib embedded to exterior surface of said plurality ofelongated rectangular steel panels.
 16. The universal structural steelpanel system according to claim 10, wherein said elongated male andfemale connecting members define a beam having a substantially U-shaped.17. The universal structural steel panel system according to claim 10,wherein said first and second connecting members are substantiallyU-shaped, said first and second connecting members having first andsecond legs fastened to first and second legs of said elongated male andfemale connecting member.
 18. A method of prefabricating a universalstructural steel panel, comprising the steps of: providing a roll ofsteel of a predetermined width; uncoiling the roll of steel; flatteningthe uncoiled steel to define a sheet of steel; slitting the sheet ofsteel at predetermined location; punching holes through the sheet ofsteel at the predetermined slots; pressing the sheet of steel andforming stiffening ribs; rolling the sheet of steel through a pluralityof rollers in a series of progress stages to bend and form elongatedmale and female connecting members at opposing side edges of the sheetof steel, wherein said elongated male connecting male is configured incomplementary mating relationship with said elongated female connectingmember of an adjacent universal structural steel panel; cutting theuniversal structural steel panel at a predetermined length; anddischarging the universal structural steel panel on a conveyor system.19. The method of prefabricating a universal structural steel panelaccording to claim 18, wherein said step of rolling the sheet of steelfurther comprised the steps of: rolling side edge portion of the sheetof steel forming said elongated female connecting member adjacent tointerior surface so that a fold is defined thereof, wherein saidelongated female connecting member extends away from the interiorsurface of the universal structural steel panel.
 20. The method ofprefabricating a universal structural steel panel according to claim 18,wherein said step of rolling the sheet of steel further comprised thesteps of: rolling side edge portion of the sheet of steel forming saidelongated male connecting member at taper to exterior surface so thatsaid elongated male connecting member is offset from exterior surfaceand extends away from the interior surface of the universal structuralsteel panel.